Assembly

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

Special Tools:

1. WARNING: Eye protection is required to be worn during use of compressed air. Failure to follow these instructions could result in possible personal injury.

Clean and dry the cylinder block.
^ Clean gasket material, dirt and debris from the cylinder block.
^ Wash the cylinder block with a suitable soap and water solution.
^ Dry the cylinder block completely using compressed air.





2. If required, install the new pipe plugs and alignment dowels.





3. Install the crankshaft key.
4. If required, on manual transaxles install a new crankshaft pilot bearing.





5. Install the upper crankshaft main bearings, the upper crankshaft thrust main bearing and the lower crankshaft main bearings.





6. Position the crankshaft.
7. Determine crankshaft main bearing clearance.
8. Apply a light coat of Super Premium 5W30 SAE Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to the crankshaft bearings and journals.





9. CAUTION: Make sure the main bearing caps are installed in their original position or engine damage may occur.

Install the main bearing caps.





10. Loosely install the bolts.





11. Tighten the bolts in the sequence shown.





12. Note: Do not remove the wedge until the crankshaft main bearing thrust cap bolts are tightened.

Wedge the crankshaft forward to fully seat the crankshaft thrust main bearings, while prying the crankshaft main bearing thrust cap to the rear.





13. Tighten the bolts.





14. Rotate the crankshaft and inspect for excessive drag or binding.
15. Inspect the crankshaft end play.





16. Note: The clearance between the lower cylinder block sealing surfaces on the crankshaft rear oil seal retainer and the crankshaft cannot exceed 0.2-0.8 mm (0.008-0.031 inch).

Install the crankshaft rear oil seal retainer.
^ Install the new crankshaft rear oil seal retainer gasket.
^ Install the crankshaft rear oil seal retainer.
^ Install the bolts.

17. Note: Lubricate the crankcase flange and the crankshaft rear oil seal bore with Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing the crankshaft front seal or damage to the crankshaft front seal may occur.

If required, replace the crankshaft front seal.





18. CAUTION: PIP mark on pistons and squirt groove on connecting rods must be located on the intake side (of the engine or possible engine damage may occur.

CAUTION: Use care when installing piston and connecting rod assemblies. Do not scratch the cylinder walls or the crankshaft journals or engine damage may occur.

CAUTION: The arrow on the piston must point toward the front of the engine or engine damage may occur.

Note: Lubricate the cylinder block, piston rings and connecting rod prior to installation with Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford Specification WSS-M2C153-G.

Install four piston and connecting rod assemblies using the Connecting Rod Guides and the Piston Ring Compressor.





19. Note: Turn the crankshaft each time to install the connecting rod caps.

Fit the connecting rod bearing.
^ Install the four upper and the four lower connecting rod bearings.
^ Inspect the connecting rod bearing to the crankshaft clearance.





20. CAUTION: Connecting rods and connecting rod caps must be properly oriented, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.

Note: Lubricate the connecting rod bearings and the crankshaft journals prior to installation with Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Note: Rotate the crankshaft after installing each connecting rod cap and inspect for excess drag or binding.

Install the four connecting rod caps.
^ Install the four connecting rod caps.
^ Install the new bolts and tighten in two steps:
^ Tighten to 35 Nm (26 ft. lbs.).
^ Tighten an additional 90 degrees.
21. Inspect the connecting rod clearance.





22. Note: The clearance between the lower cylinder block sealing surfaces on the oil pump and the cylinder block cannot exceed 0.3-0.8 mm (0.012-0.031 inch).

^ Install the new oil pump gasket.
^ Install the oil pump.

23. CAUTION: The lower engine block must be installed and the bolts tightened to specification within four minutes of sealant application or possible leakage may occur.

Apply a 3 mm (0. 1 inch) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification )VSE-M4G323-A4 sealer in four places where the oil seal retainers meet the cylinder block.





24. Install a gasket and the lower cylinder block. Tighten the bolts in two steps in the sequence shown.
^ Tighten the bolts to 7-13 Nm (62-115 inch lbs.).
^ Tighten the bolts to 20-24Nm (15-17 ft. lbs.).





25. Install the oil pump cover and screen.
^ Install new oil pump inlet tube gasket.
^ Install the oil pump cover and screen.





26. Note: The oil pan must be installed and the bolts tightened to specification within four minutes of sealant application.

Apply a 3 mm (0.1 inch) bead of Silicone Gasket and Sealant F7AZ-19554-E A or equivalent meeting Ford specification WSE-M4G323-A4.





27. Install the oil pan. Tighten the bolts in the sequence shown.





28. Install the Crankshaft position sensor (CKP sensor) and bushing.
29. Turn the engine upright on stand.
30. Install the water pump housing.
31. Assemble the cylinder head.





32. CAUTION: The bolts are torque-to-yield and must be replaced or engine damage may occur.

Tighten the bolts in three steps in the sequence shown.
^ Tighten the bolts to 15-21.5 Nm (12-18 ft. lbs.).
^ Tighten the bolts to 35-45 Nm (26-33 ft. lbs.).
^ Tighten the bolts an additional 105 degrees.
33. Loosely install the crankshaft pulley, then position the engine at top dead center cylinder No. 1.





34. Note: Lubricate the valve tappets prior to installation with Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Note: If valve tappets are being reused the valve tappet must be installed in its original position or engine damage may occur. Mark the valve tappet for proper location.

Install valve tappets.
35. Select and install valve clearance shims.





36. Install the oil control solenoid and bushing on the exhaust camshaft.





37. CAUTION: The engine must be at top dead center or engine performance may suffer.

Install the camshafts.
38. Install the camshaft front oil seals.





39. CAUTION: The cylinder head camshaft journal thrust cap must be installed first to properly position the camshaft in the cylinder head.

Note: Apply a bead of Gasket Maker F8AZ-1913508-AB or equivalent meeting Ford specification WSK-M2G348-A5 to the sealing surfaces of the front camshaft journal thrust cap prior to installation.

Note: Lubricate the camshaft bearing surfaces with Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to assembly.

Install the camshaft journal thrust caps.





40. Install the camshaft journal cap bolts. Tighten the bolts in several two-step passes in the sequence shown.
41. Turn the oil control solenoid bushing one full turn and inspect for binding.





42. Install the timing belt cover backplate.
43. Position the single hole in the bushing at the 12 o'clock position.





44. Install the timing belt routing pulleys.





45. Install the timing belt guide and crankshaft sprocket.





46. Install the bolts. Tighten the bolts in the sequence shown.





47. Note: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block.

Position the crankshaft just prior to top dead center.





48. Install the crankshaft TDC Timing Peg.





49. Rotate the crankshaft clockwise against the peg.





50. Note: Installation of the alignment tool into the exhaust camshaft may require the camshaft to be rotated clockwise.

Install the Camshaft Alignment Timing Tool on the back of the camshafts.
51. Install the intake timing sprocket and loosely install the bolt.





52. Rotate the oil control bushing one full turn and inspect for binding. Position the bushing with the single hole in the 12 o'clock position.
53. Install a new exhaust sprocket O-ring into the exhaust sprocket.





54. Install the exhaust camshaft sprocket. Make sure that the tab on the sprocket engages the hole previously positioned at 12 o'clock in the oil control solenoid bushing. Loosely install the bolt.
55. Loosely install the timing belt tensioner.





56. Install the timing belt.





57. Engage the timing belt tensioner tab into the upper timing cover backplate.





58. Using a 6 mm Allen wrench, adjust the timing belt tensioner until the index marks are aligned. Tighten the bolt.





59. CAUTION: The camshaft must be held stationary with an open-end wrench. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.

Tighten the bolt on the intake camshaft sprocket.





60. CAUTION: The camshaft must be held stationary with an open-end wrench. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.

Tighten the bolt on the exhaust camshaft sprocket in three steps.
^ Tighten the bolt to 50 Nm (36 ft. lbs.).
^ Remove the TDC peg and the Camshaft Alignment Timing Tool.
^ Tighten the bolt to 115-125 Nm (85-92 ft. lbs.).





61. Install the TDC timing peg and turn the crankshaft against the peg.





62. Note: Installation of the alignment tool into the exhaust camshaft may require the camshaft to be rotated clockwise. If the alignment tool does not align and install in the camshafts, repeat Steps 47 through 62.

Install the Camshaft Alignment Timing Tool on the back of the camshafts.
63. Remove the alignment tool and the TDC timing peg.





64. Install the bolt.





65. Install the lower timing belt cover.





66. Note: Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the crankshaft pulley keyway prior to installing the crankshaft pulley.

Install the crankshaft pulley.
67. Remove the holding tools.
68. Install the oil plug on the variable camshaft timing assembly.





69. Install the center timing belt cover.





70. Install the knock sensor.





71. Note: Inspect camshaft position sensor O-ring and replace if necessary.

Install the Camshaft Position Sensor (CMP sensor).
72. Install the water pump pulley.





73. Note: If the original spark plugs are being reused, install the spark plugs in their original locations.

Install the four spark plugs.
74. Clean the cylinder head-to-valve cover sealing surfaces.





75. Note: Apply a 3 mm (0.1 inch) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the front camshaft journal cap to cylinder head seam and install the valve cover within four minutes.

Install the valve cover.
^ Install the valve cover gasket on the valve cover.
^ Install the valve cover.
^ Position the O-rings.
^ Position the grommets.
^ Position the spacers.
^ Install and tighten the bolts.





76. Install the upper timing belt cover.
77. Install the power steering pump and brackets.
78. Install the ignition coil, radio ignition interference capacitor and bracket.





79. Install the intake manifold.
^ Install the intake manifold gaskets.
^ Install the intake manifold.
^ Install the bolts and nuts.
^ Tighten in sequence shown.
80. Install the fuel charging wiring.





81. Note: Apply Ford Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A to the threads on the bolt.

Install the oil level indicator tube.





82. Install the oil separator.
^ Install a new oil separator to cylinder block gasket.
^ Install the oil separator.
83. Install the crankcase ventilation tube.





84. Install the water bypass tube.
85. Install the water thermostat housing.
86. Install the fuel injection supply manifold.
87. Install the throttle body.





88. Install the exhaust manifold.
^ Install the new exhaust manifold gasket.
^ Install the exhaust manifold.
^ Install the nine nuts.
^ Tighten the nuts in the sequence shown.





89. Install the exhaust manifold heat shield.
90. Connect the fuel charging wiring to the fuel temperature sensor, fuel pressure sensor, exhaust oxygen sensor, the camshaft position sensor and the Throttle Position Sensor (TP sensor).
91. Install the generator mounting bracket.
92. Install the Generator (GEN) and bracket as an assembly.
93. Install the battery ground cable.
94. Install the A/C compressor.





95. Install the ignition wires.
96. On early production vehicles, install the oil control solenoid boot into the engine appearance cover.
97. Connect the fuel charging wiring to the oil control solenoid.





98. On early production vehicles, install the engine appearance cover.
99. Install the drive belt.
100. Tighten the bolts.
101. Remove the engine from the Engine Stand using the Heavy Duty Floor Crane.
102. Install the rear engine cover plate and dowels.
103. Install the flywheel.